OndoSense introduces FurnaceProtect, a radar-based level monitoring system for molten aluminium, steel, and copper, offering improved accuracy and safety without radiation in harsh industrial conditions.
OndoSense has introduced a radar-based level monitoring system designed for molten aluminium, steel and copper in closed melting, casting and holding furnaces, targeting a long-standing automation challenge in metal processing: reliable measurement in extreme heat and obscured conditions.
The company says the FurnaceProtect system can read fill levels from outside the furnace through an opening of about 50 mm in the lid, avoiding direct contact with the melt. According to OndoSense, the sensor can achieve accuracy of up to 0.3 mm while operating amid dust, steam, smoke, vibration and metal temperatures reaching 1,600C.
A key selling point is the combination of a high measurement rate and filtering software intended to keep readings stable even when the molten metal is moving, bubbling or changing rapidly during the melt cycle. OndoSense says this should help operators track when charge material has fully liquefied, rather than relying on less precise methods that can be affected by the furnace environment.
The company argues that more accurate level data can improve process control, cut the risk of overfilling and reduce unnecessary energy use and raw material consumption. For industrial decarbonisation teams, that matters because tighter control of melting operations can support lower energy demand and fewer losses in metal recovery and remelting workflows.
OndoSense positions the system as an alternative to radiometric measurement, which remains common in some harsh applications but comes with regulatory burdens because of radioactive sources. The company says its radar approach avoids the need for radiation protection procedures and repeated recalibration for different alloys or wall thicknesses.
According to the company, the device is built on its apex Level Line radar platform and is intended for simple integration. It includes a Profinet or 4-20 mA interface, digital outputs and web-based configuration software with pre-set application profiles. OndoSense also says the unit is protected by a housing mounted on the furnace lid, with optional air cooling available for more demanding installations.
The same sensor family is already being promoted for wider use across metal processing, including ladles, crucibles, casting moulds, launders and channels, as well as other industrial settings such as mining and bulk solids handling. That broader positioning suggests OndoSense is aiming to turn a niche molten-metal application into part of a wider push for radar-based sensing in difficult industrial environments.
- https://www.openpr.com/news/4562075/new-radar-solution-for-level-monitoring-in-closed-melting – Please view link – unable to able to access data
- https://express-press-release.net/news/2025/05/25/1690461 – OndoSense has developed a radar-based level measurement system for molten metals, offering high precision and stability. The system reliably measures levels of steel, aluminium, or copper at temperatures up to 1600°C, even in the presence of dust, fumes, smoke, vibrations, or sparks. Active cooling is typically unnecessary, simplifying commissioning. The solution is based on the OndoSense apex radar sensor, featuring a measurement accuracy of up to 300 µm, a measurement rate of 300 Hz, and a measurement range of 0.1 to 15 metres. This technology enhances productivity, reduces costs, and automates safety-critical processes, contributing to lower CO₂ emissions in the metal processing industry. Applications include measuring the width and thickness of semi-finished metal products in rolling mills, positioning deslagging machines in batch furnaces, and monitoring the position of steel strips in coating or picking systems. The radar sensor is also suitable for other industries and areas with challenging production environments, such as mining, mechanical and plant engineering, or the energy sector.
- https://www.computer-automation.de/sensor-technology/level-measurement-of-liquid-metal.htm – OndoSense has developed a sensor solution for measuring the level of liquid metal with unprecedented precision and reliability. The robust and low-maintenance radar system reliably measures levels of steel, aluminium, or copper at temperatures up to 1600°C, even in the presence of dust, vapours, smoke, vibrations, or sparks. As a rule, the sensor does not need to be actively cooled, which significantly simplifies commissioning. The solution is based on the ‘apex’ radar sensor from OndoSense and offers a measuring accuracy of up to 300 μm, a measuring rate of 300 Hz, and a measuring range of 0.1 to 15 m. The radar solution makes it possible to automate safety-relevant processes that could pose a risk to operators. The sensor solution for level measurement is suitable for melting pots, ladles, and tubs as well as for melting furnaces or casting moulds. As a general rule, active cooling of the level radar is unnecessary: ‘A protective window made of ceramic usually offers sufficient heat protection without affecting the high accuracy and quality of the measurements. For special cases, we have developed an optional heavy-duty housing to shield the sensor electronics against extreme heat,’ says Mathias Klenner. In addition to measuring the level of liquid metal, the sensor’s range of applications includes measuring the width and thickness of semi-finished metal products in rolling mills, positioning deslagging machines in batch furnaces, and monitoring the position of the steel strip in the coating or picking system. The radar sensor is also suitable for other industries and areas of application with adverse production environments, such as the mining industry, mechanical and plant engineering, or the energy sector.
- https://www.newstag.de/2026/06/26/neue-radarloesung-zur-fuellstandskontrolle-in-geschlossenen-schmelzoefen/ – OndoSense has developed a measurement system for the level monitoring of molten aluminium, steel, or copper inside closed furnaces. The new OndoSense FurnaceProtect radar solution measures the fill level in closed melting, casting, and holding furnaces from the outside through a small opening in the furnace lid of only approximately 50 mm. The radar system offers a measurement accuracy of up to 0.3 mm, even in the presence of dust, steam, smoke, vibrations, and metal temperatures of up to 1600 degrees Celsius. Significant fluctuations in fill levels during the melting process do not affect the measurement precision or reliability. This is due to the unique combination of a high measurement rate (500 Hz) and smart filter algorithms inherent in OndoSense radar technology. The level monitoring system therefore consistently delivers error-free, highly accurate, and rapid measurements, even in the presence of wave motion, bubble formation, or other abrupt fill level fluctuations. Based on the OndoSense apex Level Line, the new OndoSense FurnaceProtect radar system not only enables higher productivity in the operation of melting, casting, and holding furnaces but also reduces energy costs, optimises raw material usage, and prevents furnace overfilling. As a result, OndoSense is setting new standards for the automation and optimisation of casting processes in the aluminium, steel, and metal industries.
- https://castingssa.com/new-radar-solution-for-level-measurement-of-liquid-metal/ – OndoSense is expanding its portfolio in the metal industry. The German radar specialist has developed a sensor solution for the level measurement of molten metal with unprecedented precision and stability. The robust and low-maintenance radar system reliably measures steel, aluminium, or copper levels at temperatures up to 1,600 degrees, even in the presence of dust, fumes, smoke, vibrations, or sparks. The sensor usually does not need to be actively cooled, which makes commissioning significantly easier. The solution is based on the OndoSense apex radar sensor and features a measurement accuracy of up to 300μm, a measurement rate of 300Hz, and a measurement range of 0.1 to 15 metres. As a result, OndoSense offers the most accurate and fastest radar sensor for the level measurement of liquid metal. The OndoSense radar solution not only contributes to increasing productivity and reducing costs but also makes it possible to automate safety-relevant processes that can pose a risk to operators. In addition, it contributes to lowering CO2 emissions in the metal processing industry. Minimal maintenance, easy commissioning, enhanced performance, and increased productivity are not the only advantages of the radar system. For instance, the minimal maintenance effort required for radar technology ensures maximum availability. Active cooling is usually not required. The sensor solution for molten metal level measurement based on the OndoSense apex radar sensor is suitable for crucibles, ladles, and troughs, as well as for furnaces or casting moulds. As a general rule, active cooling of the level radar is unnecessary: ‘A protective window made of ceramic usually offers sufficient heat protection without affecting the high accuracy and quality of the measurements. We have developed an optional heavy-duty housing for special cases to shield the sensor electronics against extreme heat,’ says Mathias Klenner.
- https://www.aluminium-journal.com/accurate-and-reliable-level-measurement-of-liquid-metal – OndoSense has developed a sensor solution for measuring the level of liquid metal with unprecedented precision and reliability. The robust and low-maintenance radar system reliably measures levels of steel, aluminium, or copper at temperatures up to 1600°C, even in the presence of dust, vapours, smoke, vibrations, or sparks. As a rule, the sensor does not need to be actively cooled, which significantly simplifies commissioning. The solution is based on the ‘apex’ radar sensor from OndoSense and offers a measuring accuracy of up to 300 μm, a measuring rate of 300 Hz, and a measuring range of 0.1 to 15 m.
Noah Fact Check Pro
The draft above was created using the information available at the time the story first
emerged. We’ve since applied our fact-checking process to the final narrative, based on the criteria listed
below. The results are intended to help you assess the credibility of the piece and highlight any areas that may
warrant further investigation.
Freshness check
Score:
3
Notes:
⚠️ The article is dated June 26, 2026, but similar content has been published as early as May 17, 2024. ([prlog.org](https://www.prlog.org/13021130-new-radar-level-sensor-solution-for-liquid-metal-with-unprecedented-accuracy-and-reliability.html?utm_source=openai)) The press release appears to be recycled, with no new information or updates. The presence of the press release on openPR.com, a platform known for hosting user-submitted content, raises concerns about the originality and freshness of the information.
Quotes check
Score:
2
Notes:
⚠️ The article includes direct quotes attributed to Rainer Waltersbacher, Co-CEO of OndoSense. However, these quotes are identical to those found in earlier publications, indicating potential reuse. No independent verification of these quotes is available, and they cannot be cross-checked with other reputable sources.
Source reliability
Score:
2
Notes:
⚠️ The primary source is a press release from OndoSense, disseminated through openPR.com. OpenPR.com is a platform that hosts user-submitted content, which may lack editorial oversight and independent verification. This raises concerns about the reliability and independence of the source.
Plausibility check
Score:
4
Notes:
⚠️ The claims about the OndoSense FurnaceProtect radar system’s capabilities are plausible and align with known technological advancements in radar-based level measurement. However, the lack of independent verification and the recycling of content from previous publications diminish the credibility of these claims.
Overall assessment
Verdict (FAIL, OPEN, PASS): FAIL
Confidence (LOW, MEDIUM, HIGH): HIGH
Summary:
The article is a recycled press release from OndoSense, disseminated through openPR.com, a platform known for hosting user-submitted content. The content lacks freshness, originality, and independent verification, with identical quotes found in earlier publications and no corroboration from other reputable sources. These factors collectively render the article unsuitable for publication under our editorial standards.
